Gearbox Question - bits found, ID needed

Post by **HarryMann** » 06 Mar 2006, 18:37

My goodness Christph, that's a big embedded image

373K, and we have a self imposed limit of about 60K here in Blighty

Post by **Cate** » 06 Mar 2006, 18:46

I'm off to get a 50" screen..........

Post by **HarryMann** » 06 Mar 2006, 18:59

Post by **SplendiferousII** » 01 Aug 2006, 08:17

I have a 1.6d type 25 2WD van and have found very very similar looking bits stuck to my gearbox drain plug magnet + 3 ball bearings about 6mm in Diameter.

Are these the same things as found above?

I will attempt to get a picture up later today but no promises.

My gearbox is currently half way out so I can open it up and fix the problem.

Could someone just give me a bit of a clearer idea as to what the problem is and how big a job is it to fix?

I will be attempting the gearbox strip and rebuild myself - so any tips would be GREATLY appreciated.

Post by **Diamond Hell** » 01 Aug 2006, 08:42

Errrr, good lucky withyour gearbox rebuild. There are a fair number of special tools required to rebuild these gearboxes. You are aware of this, aren't you?

The bits I found were in consequential, but finding bearings plus metal suggests you have a collapsed bearing race. You may well find that this part will need pressing off and then on.

If you have experience in rebuildiing gearboxes then good luck. If this is your first one then I hope you have plenty of tools and a Bentley manual to hand.

Post by **SplendiferousII** » 01 Aug 2006, 11:38

Well I'm aware of a few special tool requiements - of which I have none! I am planning to make / tackle these issues as I go. Luckily I am a mechanical engineer, so I hope this will stand me in good steed.

I read that Simon Baxter says these bits are often found stuck to the drain plug magnet and that its all part of the course and never seems to cause problems.

So am toying with the idea of leaving well alone? - But I don't want problems further down the line!

A stitch in time and all that! - Which way do I jump I ask? Leave it or fix it? Ummmmm The box is halfway out!

Are these even the bits simon is talking about?

Post by **Diamond Hell** » 01 Aug 2006, 11:45

If it ain't broke, don't fix it!

Unless you've got good reason to pull the box to piece (like it's making horrible noises etc) then leave well alone and deal with the problems when they arise.

Post by **SplendiferousII** » 01 Aug 2006, 11:51

Well I like your thinking. And it does run perfectly with no noises or gear shift problems at all. Only thing is, I want the van to be 100% reliable and don't want to be worrying about it going wrong half way down to spain. If I knew this was a common problem and that leaving it well alone would be fine and dandy - that's what I would do. But as I'm really unsure - I'd better fix it. ???????????? Confused now.

Post by **HarryMann** » 01 Aug 2006, 12:07

You can never be really sure though, you know that

It isn't completely right nor is it completely wrong...

Technicians only know what they know, but Engineers know what they don't know

So you should know that you don't know (for sure) whats going to happen - the grey mist of another compromise.

You could stick (as in glue) a few good magnets on the bottom to keep any loose bits down where they can't do any harm

Post by **SplendiferousII** » 01 Aug 2006, 12:17

And thats the problem - I am an engineer! And I dont know what it is or what it does. But I'm pretty sure VW engineers would not put a bit in which breaks which didnt really mater. - Make sence?

I need to change my clutch anyway as the van judders badly when I pull away. So I'll pop the box out anyway.

I'll pull the end cover off and have a look in there and see if I can see anything missing or wobbling.

I would think the bit has something to do with the selectors and act as a linear bearing or something.

I have no doubt that the balls dont belong to the gear train as these would only ever be needle or taper roller bearings.

Best go in and take a look I thinks.

Any tips on going in there? - I've drained the oil - that will save a mess on the garage floor at least.

Post by **HarryMann** » 01 Aug 2006, 12:55

I have no doubt that the balls dont belong to the gear train as these would only ever be needle or taper roller bearings.

Nope, there's big ball bearings in there, as well as doble-row ball bearings... but those arts are as beaker said early on in this thread, a kind of linear bearing, and one which is probably the detent mechanism for helping to hold it in the selected gear. So if its not as snickety a change as you'd imagine, thats why.

Careful you don't get any bits where they might do harm when you turn it upside down and jiggle it all a round... theres a fair quantity of oil that doesn't come out the drain plug, due a baffle, that requires upending it. Few mechanics take these boxes apart and rebuild them, they tend to leave that to those experienced with gearbox strips and builds ... if yu have a spare to drop in, then thats puts a diffeernt light on it. I doubt any more subtle hints will be given.... good luck

Post by **Diamond Hell** » 01 Aug 2006, 13:02

I want the van to be 100% reliable

You sure you're an engineer?

Surely an engineer would be concerned with how many 9's they were aiming at reliability-wise as 100% is simply never achieveable!

You're also talking about a 15-25 year old van. I would have thought 99.0% reliability would be rather hopeful. Sudden and dramatic failures at this sort of age are not unexpected.

Post by **SplendiferousII** » 01 Aug 2006, 13:05

Harry - your scaring me now! I've rebuilt a MG midget gear box before, but I doubt that will put me in good steed for a VW box.

I'll be a happy man when this stage of my life is over.

Post by **SplendiferousII** » 01 Aug 2006, 13:07

Diamond Hell wrote:
I want the van to be 100% reliable

You sure you're an engineer?

Surely an engineer would be concerned with how many 9's they were aiming at reliability-wise as 100% is simply never achieveable!

You're also talking about a 15-25 year old van. I would have thought 99.0% reliability would be rather hopeful. Sudden and dramatic failures at this sort of age are not unexpected.

Point taken! 100% reliable being a term. Lets go for 89% then eh!

Post by **HarryMann** » 01 Aug 2006, 22:00

I've rebuilt a MG midget gear box before

Haha! So have I, and a few mini coopers (you know the proper ones), but they don't have a hypoid diff in the middle of them.

You will need a set of seals and bearings to make any great improvement . Some of the bearings are always changed, as they're always worn. You will need a late series or new 3/4th syncro hub, as to gtake it apart and not change that would be a shame too - allegedly.

Keep in touch... and order your parts early, unfort. they can't be had just around the corner.